Model:
DR250 / DR-250 / SP250
Model Variant Codes:
DR250, DR-Z250 (though the manual explicitly lists DR250/DR-250/SP250, later iterations might be confused with DR-Z. However, this manual targets the earlier air-cooled models).
Covered Years:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989
Target Audience:
Owners and independent mechanics seeking to perform maintenance, repairs, and diagnostics on Suzuki DR250 series dual-sport motorcycles.
Value Proposition:
Provides significant cost savings by enabling DIY repairs, empowering users with the same information used by professional technicians.
Ease Of Use:
Presents information with step-by-step instructions and accompanying illustrations for straightforward comprehension.
Accessibility:
Instant email delivery and multi-device compatibility enhance usability and immediate access to critical repair data.
Scope:
Complete Workshop Service and Repair procedures for all aspects of the Suzuki DR250/DR-250/SP250 models from 1982-1989.
Estimated Pages:
Detailed, likely exceeding 300 pages based on typical comprehensive workshop manuals of this era.
Type:
Workshop Service Repair Manual
Primary Language:
English
Delivery Format:
Downloadable Digital Format (PDF recommended for printing and device compatibility)
Powertrain:
Engine overhaul, top-end rebuild, bottom-end assembly, ignition system, carburetor tuning, fuel delivery, exhaust system.
Chassis And Suspension:
Front fork service and seal replacement, rear shock absorber maintenance, swingarm and bearing service, steering head bearing service.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, charging system (stator, rectifier/regulator), starter motor, battery maintenance, troubleshooting electrical faults.
Body And Frame:
Frame inspection, bodywork repair and alignment, seat replacement, fender installation.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, chain adjustment, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for all repair tasks, from minor adjustments to complete engine rebuilds.
Special Tools:
Identification and use of special tools required for specific repair procedures.
Diagnostic Capabilities:
Advanced diagnostic procedures for engine, electrical, and mechanical systems, including component testing and specifications.
Rebuild Procedures:
Comprehensive engine and transmission rebuild instructions, including torque specifications, clearance measurements, and assembly sequences.
Customization And Modification:
While primarily focused on stock repair, it provides the foundational knowledge for performance tuning and modifications.
Compatibility:
Compatible with all PC and MAC computers, tablets, and mobile phones. Requires Adobe Reader (free download).
Resolution And Clarity:
High-quality digital reproduction of original factory documentation, ensuring clear text and legible diagrams/images.
Digital Binding:
N/A (Digital Format) - Allows for printing of selected sections or the entire manual.
Digital Paper Type:
N/A (Digital Format) - User can print on preferred paper type.
Engine Type:
Air-cooled, four-stroke, single-cylinder SOHC (Single Overhead Camshaft)
Displacement:
Approximately 249 cc (exact figure may vary slightly by specific model year and tuning)
Horsepower Range:
Estimated 20-25 HP (horsepower) at peak RPM, dependent on specific year and tuning.
Torque Figure:
Torque figures typically in the range of 15-18 lb-ft, specific figures will be detailed in the manual.
Carburetor Type:
Single Mikuni carburetor (specific model number like VM28SS or similar will be listed).
Fuel Grade:
Unleaded gasoline, typically 87 octane (octane rating to be confirmed in manual).
Ignition Type:
CDI (Capacitor Discharge Ignition)
Type:
Constant mesh, 5-speed or 6-speed sequential manual transmission (manual will specify).
Availability:
No automatic or other optional transmission types were offered for this model.
Clutch Type:
Wet, multiple-disc clutch operated by cable.
Transmission Oil Type:
Suzuki recommends SAE 10W-40 or SAE 20W-40 motorcycle-specific engine oil for the transmission and wet clutch. Manual will provide exact Suzuki specification.
Overall Length:
Variable by year, approximately 2100-2200 mm (specific figures will be in the manual).
Overall Width:
Variable by year, approximately 800-900 mm (specific figures will be in the manual).
Seat Height:
Variable by year, typically around 860-890 mm (specific figures will be in the manual).
Dry Weight:
Approximately 110-125 kg (242-275 lbs), depending on specific year and equipment (manual will confirm).
Fuel Capacity:
Approximately 10-12 liters (2.6-3.2 US gallons), including a reserve (manual will specify exact capacity).
Crash Test Data:
Not applicable for this era and type of motorcycle; safety features focus on active safety through design and rider control.
Braking System:
Front disc brake and rear drum brake (some later models or variations might have a rear disc, the manual will clarify this). Effective stopping power for its class.
Suspension:
Robust telescopic front forks and a rear monoshock or twin-shock system providing stability and control over varied terrain.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility and signaling.
Display Features:
Basic analog instrumentation including speedometer, tachometer (on some models), odometer, trip meter, and indicator lights.
ABS Availability:
ABS (Anti-lock Braking System) was not available on models from this era.
Bluetooth Or Usb:
Not applicable for this model and era of motorcycle.
Oil Change Interval:
Typically every 3,000 km (approx. 1,860 miles) or annually, whichever comes first. Manual will provide precise intervals and conditions.
Air Filter Cleaning:
Recommended every 1,000 km (approx. 620 miles) or more frequently in dusty conditions. Manual details cleaning and oiling procedure.
Spark Plug Replacement:
Intervals typically around 6,000-10,000 km (approx. 3,700-6,200 miles), or as needed based on condition. Manual specifies correct plug type and gap.
Engine Oil Capacity:
Approximately 1.6 - 1.8 liters (1.7 - 1.9 US quarts) with oil filter change. Manual will provide exact capacity and fill level checks.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact type required for optimal performance and compatibility.
Carburetor Clogging:
Common with older carbureted motorcycles, requiring regular cleaning and proper fuel storage to prevent varnish buildup.
Suspension Seal Leaks:
Front fork seals can degrade over time, leading to oil leaks. The manual provides detailed instructions for replacement.
Electrical Connections:
Corrosion on electrical connectors can cause intermittent issues. Manual assists in locating and cleaning these connections.
Suzuki Off Road Legacy:
Suzuki has a long and successful history in off-road and dual-sport motorcycling, with the DR series being a cornerstone of their lineup.
Dr250 Lineage:
The DR250 and its variants were developed as versatile dual-sport machines, bridging the gap between on-road usability and off-road capability. The SP designation often indicated sport or special editions. This generation represents a crucial period in the evolution of the dual-sport motorcycle.
Manufacturing Location:
Primarily manufactured in Japan by Suzuki Motor Corporation.
